Shingle with reinforced nail zone and method of manufacturing

ABSTRACT

A roofing shingle is provided. The roofing shingles includes an overlay sheet including a headlap portion and a tab portion and an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet. A reinforcement material is secured to the headlap portion of the overlay sheet. The reinforcement material is configured to improve nail pull-through. The reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a distance of about 0.12 inches or less.

RELATED APPLICATIONS

This application is a continuation application of U.S. Ser. No.14/267,956, filed May 2, 2014, titled SHINGLE WITH REINFORCEMENT NAILZONE AND METHOD OF MANUFACTURING, which is a continuation application ofU.S. Ser. No. 14/105,913, filed Dec. 13, 2013, titled SHINGLE WITHREINFORCED NAIL ZONE AND METHOD OF MANUFACTURING, now U.S. Pat. No.8,752,351, which is a continuation application of U.S. Ser. No.13/097,810, filed Apr. 29, 2011, titled SHINGLE WITH REINFORCED NAILZONE AND METHOD OF MANUFACTURING, now U.S. Pat. No. 8,607,521, which isa continuation-in-part patent application of U.S. patent applicationSer. No. 12/895,195, filed Sep. 30, 2010, titled SHINGLE WITH REINFORCEDNAIL ZONE AND METHOD OF MANUFACTURING, now U.S. Pat. No. 8,141,413,which is a continuation of U.S. Ser. No. 11/198,522, filed Aug. 5, 2005,titled SHINGLE WITH REINFORCED NAIL ZONE AND METHOD OF MANUFACTURING,now U.S. Pat. No. 7,836,654, the entire disclosures of which areincorporated herein by reference.

TECHNICAL FIELD

This invention relates to a shingle, such as a roofing shingle, and inparticular, to a roofing shingle having an improved nail zone.

BACKGROUND OF THE INVENTION

Asphalt-based roofing materials, such as roofing shingles, roll roofingand commercial roofing, are installed on the roofs of buildings toprovide protection from the elements, and to give the roof anaesthetically pleasing look. Typically, the roofing material isconstructed of a substrate such as a glass fiber mat or an organic felt,an asphalt coating on the substrate, and a surface layer of granulesembedded in the asphalt coating.

A common method for the manufacture of asphalt shingles is theproduction of a continuous sheet of asphalt material followed by ashingle cutting operation, which cuts the material into individualshingles. In the production of asphalt sheet material, either a glassfiber mat or an organic felt mat is passed through a coater containinghot liquid asphalt to form a tacky, asphalt coated sheet. Subsequently,the hot asphalt coated sheet is passed beneath one or more granuleapplicators, which discharge protective and decorative surface granulesonto portions of the asphalt sheet material.

In certain types of shingles, it is especially desired that the shinglesdefine a sufficiently wide area, often known in the industry as the“nail zone,” in order to make installation of roofs using shingles, suchas laminated shingles, more efficient and secure. One or more lines orother indicia painted or otherwise marked longitudinally on the surfaceof the shingle may define such a nail zone. It is especially desiredthat the shingles define a nail zone that allows the installers to havesome latitude in the nail placement.

Additionally, the leading edge of some shingles may experience lift offin high wind situations. Therefore, there is also a need for shingleswhere the shingles have a sufficiently high nail pull-through value sothat the installed shingles have improved performance in high windsituations.

SUMMARY OF THE INVENTION

The above objects as well as other objects not specifically enumeratedare achieved by a roofing shingle. The roofing shingles includes anoverlay sheet including a headlap portion and a tab portion and anunderlay sheet secured to the overlay sheet such that a region of theunderlay sheet overlaps a region of the headlap portion of the overlaysheet. A reinforcement material is secured to the headlap portion of theoverlay sheet. The reinforcement material is configured to improve nailpull-through. The reinforcement material extends beyond the overlappingregions of the headlap portion and the underlay sheet a distance ofabout 0.12 inches or less.

According to this invention there is also provided a roofing shingleincluding an overlay sheet having a headlap portion and a tab portion.The overlay sheet has an overlay sheet height. An underlay sheet issecured to the overlay sheet such that a region of the underlay sheetoverlaps a region of the headlap portion of the overlay sheet. Theunderlay sheet has a height equal to half of the overlay sheet height ±⅛inch. A reinforcement material is secured to the headlap portion of theoverlay sheet. The reinforcement material is configured to improve nailpull-through. The reinforcement material extends beyond the overlappingregions of the headlap portion and the underlay sheet a distance ofabout 0.12 inches or less.

According to this invention there is also provided a roofing shingleincluding an overlay sheet including a headlap portion and a tab portionand an underlay sheet secured to the overlay sheet such that a region ofthe underlay sheet overlaps a region of the headlap portion of theoverlay sheet. A reinforcement material is secured to the headlapportion. The reinforcement material is configured to improve nailpull-through. The reinforcement material has a height. The overlappingregions of the underlay sheet and the headlap portion of the overlaysheet have a height. The ratio of the height of the overlapping regionsto the height of the reinforcement material is in a range of from about70% to about 100%.

According to this invention there is also provided a roofing shinglehaving an overlay sheet including a headlap portion and a tab portion.The tab portion includes a plurality of cutouts and the plurality ofcutouts has an upper edge. An underlay sheet is secured to the overlaysheet such that a region of the underlay sheet overlaps a region of theheadlap portion of the overlay sheet. A reinforcement material issecured to the headlap portion. The reinforcement material is configuredto improve nail pull-through. The reinforcement material has a loweredge and the distance from the upper edge of the plurality of thecutouts to the lower edge of the reinforcement material is about 0.25inches or less.

Various objects and advantages of this invention will become apparent tothose skilled in the art from the following detailed description of thevarious embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic elevational view of an apparatus for makingshingles according to the invention.

FIG. 2 is a perspective view of a laminated shingle having areinforcement member in accordance with this invention.

FIG. 3 is a schematic sectional view of a pair of laminated roofingshingles of the prior art stacked together, shown in exaggeratedthickness to illustrate humping of the stacked shingles.

FIG. 4 is a schematic sectional view of a pair of laminated roofingshingles according to the invention stacked together, shown inexaggerated thickness to illustrate how the reinforcement members ofadjacent shingles cooperate to reduce humping of the stacked shingles.

FIG. 5 is a cross-sectional view, in elevation, of a second embodimentof a laminated shingle having reinforcement material.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, there is shown in FIG. 1 an apparatus 10for manufacturing an asphalt-based roofing material according to theinvention. In the illustrated embodiment, the manufacturing processinvolves passing a continuous sheet 12 in a machine direction (indicatedby the arrows) through a series of manufacturing operations. The sheetusually moves at a speed of at least about 200 feet/minute (61meters/minute), and typically at a speed within the range of betweenabout 450 feet/minute (137 meters/minute) and about 800 feet/minute (244meters/minute). The sheet, however, may move at any desired speed.

In a first step of the illustrated manufacturing process, a continuoussheet of substrate or shingle mat 12 is payed out from a roll 14. Thesubstrate can be any type known for use in reinforcing asphalt-basedroofing materials, such as a non-woven web of glass fibers. The shinglemat 12 may be fed through a coater 16 where an asphalt coating isapplied to the mat 12. The asphalt coating can be applied in anysuitable manner. In the illustrated embodiment, the mat 12 contacts aroller 17, that is in contact with a supply of hot, melted asphalt. Theroller 17 completely covers the mat 12 with a tacky coating of hot,melted asphalt to define a first asphalt coated sheet 18. In otherembodiments, however, the asphalt coating could be sprayed on, rolledon, or applied to the sheet by other means. Typically, the asphaltmaterial is highly filled with a ground stone filler material, amountingto at least about 60 percent by weight of the asphalt/fillercombination.

A continuous strip of a reinforcement material or tape 19, as will bedescribed in detail herein, may then be payed out from a roll 20. Thereinforcement tape 19 adheres to the first asphalt coated sheet 18 todefine a second asphalt coated sheet 22. In one embodiment, thereinforcement tape 19 is attached to the sheet 18 by the adhesivemixture of the asphalt in the first asphalt coated sheet 18. Thereinforcement tape 19, however, may be attached to the sheet 18 by anysuitable means, such as other adhesives. In one embodiment, the tape 19is formed from polyester. In another embodiment, the tape 19 is formedfrom polyolefin, such as polypropylene or polyethylene. The tape 19,however, can be formed from any material for reinforcing andstrengthening the nail zone of a shingle, such as, for example, paper,film, scrim material, and woven or non-woven glass.

The resulting second asphalt coated sheet 22 may then be passed beneatha series of granule dispensers 24 for the application of granules to theupper surface of the second asphalt coated sheet 22. The granuledispensers can be of any type suitable for depositing granules onto theasphalt coated sheet. A granule dispenser that can be used is a granulevalve of the type disclosed in U.S. Pat. No. 6,610,147 to Aschenbeck.The initial granule blender 26 may deposit partial blend drops ofbackground granules of a first color blend on the tab portion of thesecond asphalt coated sheet 22 in a pattern that sets or establishes thetrailing edge of subsequent blend drops of a second color blend (of anaccent color) and a third color blend (of a different accent color). Forpurposes of this patent application, the first color blend and thebackground granules are synonymous. The use of initially applied partialblend drops to define the trailing edge of subsequent blend drops isuseful where accurate or sharp leading edges are possible, but accuratetrailing edges at high shingle manufacturing speeds are difficult.

As is well known in the art, blend drops applied to the asphalt coatedsheet are often made up of granules of several different colors. Forexample, one particular blend drop that is supposed to simulate aweathered wood appearance might actually consist of some brown granules,some dark gray granules, and some light gray granules. When thesegranules are mixed together and applied to the sheet in a generallyuniformly mixed manner, the overall appearance of weathered wood isachieved. For this reason, the blend drops are referred to as having acolor blend, which gives an overall color appearance. This overallappearance may be different from any of the actual colors of thegranules in the color blend. Also, blend drops of darker and lightershades of the same color, such as, for example, dark gray and lightgray, are referred to as different color blends rather than merelydifferent shades of one color.

As shown in FIG. 1, the series of dispensers 24 includes four colorblend blenders 26, 28, 30, and 32. Any desired number of blenders,however, can be used. The final blender may be the background blender34. Each of the blenders may be supplied with granules from sources ofgranules, not shown. After the blend drops are deposited on the secondasphalt coated sheet 22, the remaining, uncovered areas are still tackywith warm, uncovered asphalt, and the background granules from thebackground blender 34 will adhere to the areas that are not alreadycovered with blend drop granules. After all the granules are depositedon the second asphalt coated sheet 22 by the series of dispensers 24,the sheet 22 becomes a granule covered sheet 40.

In one embodiment, the reinforcement tape 19 includes an upper surfaceto which granules substantially will not adhere. The reinforcement tape19, however, may include an upper surface to which granules will adhere.For example, the apparatus 10 may include any desired means fordepositing granules onto substantially the entire second asphalt coatedsheet 22, except for the portion of the second asphalt coated sheet 22covered by the tape 19, as best shown in FIG. 2. Alternately, granulesmay be deposited onto substantially the entire second asphalt coatedsheet 22, including the tape 19, but wherein the reinforcement tape 19includes an upper surface to which granules substantially will notadhere.

The granule covered sheet 40 may then be turned around a slate drum 44to press the granules into the asphalt coating and to temporarily invertthe sheet so that the excess granules will fall off and will berecovered and reused. Typically, the granules applied by the backgroundblender 34 are made up by collecting the backfall granules falling fromthe slate drum 44.

The granule covered sheet 40 may subsequently be fed through a rotarypattern cutter 52, which includes a bladed cutting cylinder 54 and abackup roll 56, as shown in FIG. 1. If desired, the pattern cutter 52can cut a series of cutouts in the tab portion of the granule coveredsheet 40, and cut a series of notches in the underlay portion of thegranule covered sheet 40.

The pattern cutter 52 may also cut the granule covered sheet 40 into acontinuous underlay sheet 66 and a continuous overlay sheet 68. Theunderlay sheet 66 may be directed to be aligned beneath the overlaysheet 68, and the two sheets may be laminated together to form acontinuous laminated sheet 70. As shown in FIG. 1, the continuousunderlay sheet 66 may be routed on a longer path than the path of thecontinuous overlay sheet 68. Further downstream, the continuouslaminated sheet 70 may be passed into contact with a rotary lengthcutter 72 that cuts the laminated sheet into individual laminatedshingles 74.

In order to facilitate synchronization of the cutting and laminatingsteps, various sensors and controls may be employed. For example,sensors, such as photo eyes 86 and 88 can be used to synchronize thecontinuous underlay sheet 66 with the continuous overlay sheet 68.Sensors 90 can also be used to synchronize the notches and cutouts ofthe continuous laminated sheet with the end cutter or length cutter 72.

In one embodiment, the reinforcement tape may be attached to the shinglemat 12 prior to the application of the asphalt coating, as shown at 19Ain FIG. 1. The tape 19A may be attached to the shingle mat 12 by anysuitable means, such as hot, melted asphalt, or other adhesives.

In another embodiment, the reinforcement tape may be attached to thegranule covered sheet 40, as shown at 19B in FIG. 1. The tape 19B may beattached to the granule covered sheet 40 by any suitable means, such ashot, melted asphalt, or other adhesives.

In another embodiment, the reinforcement tape may be attached to a lowersurface (downwardly facing as viewed in FIG. 1) of the mat 12, the firstasphalt coated sheet 18, the second asphalt coated sheet 22, or thegranule covered sheet 40, as shown at 19C and 19D in FIG. 1. The tape19C may be attached to the mat 12, the first asphalt coated sheet 18,the second asphalt coated sheet 22, or the granule covered sheet 40 byany suitable means, such as hot, melted asphalt, other adhesives, orsuitable fasteners. In such an embodiment, the reinforcement tape 19Cand 19D may be attached to the lower surface of the nail zone of eitherof the overlay sheet 68 or the underlay sheet 66, thereby reinforcingand strengthening the nail zone as described herein.

It will be understood, however, that in any of the embodiments describedherein, reinforcement material may be applied as an extruded or liquidmaterial, such as a polymer, that will adhere to the mat 12, the firstsheet 18, the second sheet 22, the granule covered sheet 40, or thelower surface of the underlay sheet 66 or the overlay sheet 68.Additionally, the reinforcement material may be applied to the laminatedroofing shingle 74, as described below.

Referring now to FIG. 2, a laminated roofing shingle is shown generallyat 74. In the illustrated embodiment, the shingle 74 includes theoverlay sheet 68 attached to the underlay sheet 66 and has a first end74A and a second end 74B. The shingle 74 also includes a longitudinalaxis A. The overlay sheet 68 may include a headlap portion 76 and a tabportion 78. The headlap portion 76 may include a lower zone 76A and anupper zone 76B. The tab portion 78 defines a plurality of tabs 80 andcutouts 82 between adjacent tabs 80. In the illustrated embodiment, thetab portion 78 includes four tabs 80, although any suitable number oftabs 80 may be provided. The headlap portion 76 and the tabs 80 mayinclude one or more granule patterns thereon. Each cutout 82 has a firstheight H1. In the illustrated embodiment, the cutouts 82 are shown ashaving the same height H1. It will be understood however, that eachcutout 82 may be of different heights. A line B is collinear with anupper edge 82A of the cutouts 82 and defines an upper limit of anexposed region 84 of the underlay sheet 66. In the illustratedembodiment, the height of the exposed region 84 is equal to the firstheight H1, although the height of the exposed region 84 may be anydesired height. In a shingle wherein the cutouts 82 have differentheights, the line B may be collinear with an upper edge 82A of thecutout 82 having the largest height. In the illustrated embodiment, theoverlay sheet 68 has a second height H2.

The reinforcement tape 19 may be disposed longitudinally on the headlapportion 76. In the illustrated embodiment, the tape 19 extendslongitudinally from the first end 74A to the second end 74B of theshingle 74 within the lower zone 76A of the headlap portion 76. A loweredge 19A of the tape 19 may be spaced apart from the line B by adistance D1, and an upper edge 19B of the tape 19 may be spaced apartfrom the line B by a distance D2. In one embodiment, the distance D1 iswithin the range of from about ¼ inch to about ¾ inch. In anotherembodiment, the distance D1 is about ½ inch. In one embodiment, thedistance D2 is within the range of from about 1¾ inches to about 2¼inches. In another embodiment, the distance D2 is about 2 inches. Thedistances D1 and D2 may, however, be of any other desired length. Forexample, if desired, the tape 19 may substantially cover the entireheadlap portion 76 of the overlay sheet 68. It will be furtherunderstood, however, that one or more additional lengths of tape may bedisposed longitudinally on the headlap portion 76, such as shown by thephantom line 19′ in FIG. 2. It will be understood that the reinforcementmaterial need not extend from the first end 74A to the second end 74B ofthe shingle 74, and may be disposed in one or more sections or portionson the shingle 74.

The tape 19 defines a nail zone 98 and may include text such as “nailhere •”, as shown in FIG. 2. It will be understood, however, that anyother text or other indicia may be included on the tape 19. It will alsobe understood that the tape 19 can be provided without such text orindicia. Such indicia on the tape 19 ensure that the nail zone 98 may beeasily and quickly identified by the shingle installer.

In the embodiment illustrated in FIG. 2, the underlay sheet 66 includesa leading edge 66A and a trailing edge 66B and has a third height H3. Inthe illustrated embodiment, the trailing edge 66B of the underlay sheet66 is spaced apart from the line B by a distance D3. As shown, thedistance D3 is about ⅜ inch, however, the distance D3 may be any desireddistance.

In the illustrated embodiment, the third height H3 of the underlay sheet66 is less than one-half the second height H2 of the overlay sheet 68.The overlay sheet 68 and the underlay sheet 66 thereby define atwo-layer portion of the laminated shingle 74 and a single-layer portionof the laminated shingle 74, wherein at least a portion of the tape 19is adhered to the single-layer portion of the laminated shingle 74.Alternately, the third height H3 of the underlay sheet 66 may be equalto one-half the second height H2 of the overlay sheet 68, or greaterthan one-half of the second height H2 of the overlay sheet 68. Such arelationship between the underlay sheet 66 and the overlay sheet 68allows the tape 19 to be positioned such that a reinforced nail zone isprovided at a substantially single-layer portion of the shingle 74.

In another embodiment of the invention, a layer of material, such astalc or sand, may be applied to the first asphalt coated sheet 18 shownin FIG. 1. The material may be applied by any desired means to an uppersurface of the first asphalt coated sheet 18. In one embodiment, thematerial may be applied to the portion of the first asphalt coated sheet18 that will become the portion of the overlay sheet 66 shown covered bythe tape 19 in FIG. 2. Such a material may reduce tackiness of theportions of the second asphalt coated sheet 22 to which the material hasbeen applied, and thereby provide a surface to which granulessubstantially will not adhere.

In the exemplary shingle 74 illustrated in FIG. 2, the shingle 74 mayhave a nail pull-through value, measured in accordance with a desiredstandard, such as prescribed by ASTM test standard D3462. For example,the shingle 74 may have a nail pull-through value that is greater thanin an otherwise identical shingle having no such tape 19. In oneembodiment, the shingle 74 may have a nail pull-through value within therange of from about ten percent to about 100 percent greater than in anotherwise identical shingle having no such tape 19. In anotherembodiment, the shingle 74 may have a nail pull-through value about 50percent greater than in an otherwise identical shingle having no suchtape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 0.5 mils, may have anail pull-through value about 13.3 percent greater than in an otherwiseidentical shingle having no such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 3.0 mils, may have anail pull-through value about 62.3 percent greater than in an otherwiseidentical shingle having no such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 4.0 mils, may have anail pull-through value about 86.0 percent greater than in an otherwiseidentical shingle having no such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 5.0 mils, may have anail pull-through value about 112.7 percent greater than in an otherwiseidentical shingle having no such tape 19.

Because there may be substantially no granules in the portion of theoverlay sheet 68 covered by the tape 19, the weight of the shingle 74may be reduced relative to an otherwise identical shingle having no suchtape 19. For example, the weight of the exemplary shingle 74 illustratedin FIG. 2, may be reduced within the range of from about four percent toabout six percent relative to the weight of an otherwise identicalshingle having no such tape 19. The material and transportation cost mayalso be reduced.

Although the invention has been disclosed in the context of a laminatedshingle 74, it will be understood that the reinforcement tape 19 may beattached to any other type of shingle, such as a single layer shingle.

As shown in FIG. 3, laminated roofing shingles 100 of the prior art arestacked in a bundle 102. Only a pair of such shingles 100 areillustrated in FIG. 3, with every other shingle 100 inverted and turned180 degrees. It will be understood, however, that the shingles 100 maybe stacked such that every other of such shingles 100 are eitherinverted or turned 180 degrees, or both. This stacking method minimizesuneven build in the bundle 102 caused by the difference in thicknessbetween the area of the shingle 100 that includes the underlay sheet 106and the area that does not include the underlay sheet 106. A problem mayoccur, however, along a central area 108 of the bundle 102 becausecentral areas 110 of the shingles 100 are double-layered, whereas thecutout portions 112 of the shingles 100 adjacent the central areas 110are single-layered. The difference in thickness causes a ridge or hump114 along the central area 108 of the bundle 102 that becomesprogressively higher as the number of shingles 100 in the bundle 102increases.

FIG. 4 is a schematic sectional view of a representative pair of stackedshingles 74 manufactured according to the present invention. As shown inFIG. 4, the laminated roofing shingles 74 are stacked such that everyother of the shingles 74 is inverted and turned 180 degrees relative toan adjacent one of the shingles 74 to define a bundle 99. It will beunderstood, however, that the shingles 74 may be stacked such that everyother of such shingles 74 are either inverted or turned 180 degrees, orboth. The bundle 99 includes a central area 92. In the illustratedembodiment, the central area 92 includes the lower zones 76A andreinforcement tape 19 of each shingle 74, and includes the portion ofeach laminated roofing shingle 74 wherein the shingle 74 isdouble-layered. In contrast to the prior art shingles 100, when thelaminated shingles 74 of the invention are stacked, the areas of theadjacent shingles 74 having no granules, such as the areas covered bythe reinforcement tapes 19, cooperate to advantageously reduce humpingin the central area 92 of the bundle of stacked shingles 74. As bestshown in FIG. 4, the central area 92 of the bundle, as represented bythe pair of shingles 74 illustrated, has a fourth height H4substantially identical to a fifth height H5 of a remainder of thebundle outside of the central area 92.

Referring now to FIG. 5, a second embodiment of a laminated roofingshingle is shown generally at 174. In the illustrated embodiment, theshingle 174 includes an overlay sheet 168 attached to an underlay sheet166. In the illustrated embodiment, the overlay sheet 168 and theunderlay sheet 166 are the same as, or similar to, the overlay sheet 68and the underlay sheet 66 described above and illustrated in FIG. 2. Inother embodiments, the overlay sheet 168 and the underlay sheet 166 canbe different from the overlay sheet 68 and the underlay sheet 66. Theshingle 174 has a first end (not shown) and a second end (not shown). Inthe illustrated embodiment, the first and second ends of the shingle 174are the same as, or similar to, the first end 74A and the second end 74Bdescribed above and illustrated in FIG. 2. In other embodiments, thefirst and second ends of the shingle 174 can be different from the firstend 74A and the second end 74B. The shingle 174 also includes alongitudinal axis extending from the first end to the second end. In theillustrated embodiment, the longitudinal axis is the same as, or similarto, the longitudinal axis A described above and illustrated in FIG. 2.In other embodiments, the longitudinal axis of the shingle 174 can bedifferent from the longitudinal axis A.

Referring again to FIG. 5, the overlay sheet 168 may include a headlapportion 176 and a tab portion 178. The headlap portion 176 may include alower zone 176A and an upper zone 176B. The tab portion 178 defines aplurality of tabs 180 and cutouts (not shown) between adjacent tabs 180.Any suitable number of tabs 180 and cutouts may be provided. The headlapportion 176 may include any type of granule applied thereon, includingheadlap granules. The tabs 180 may include one or more granule patternsapplied thereon. In the illustrated embodiment, the shingle 174 can beformed in the same manner, or in a similar, manner to the manufacturingprocess described above and illustrated in FIG. 1. In other embodiments,the shingle 174 can be formed with other desired processes.

Referring again to FIG. 5, each cutout has a first height H101. Itshould be understood that the cutouts may be of the same first heightH101 or different cutouts can have different first heights H101. Thecutouts have an upper edge 182A that defines an upper limit of anexposed region (not shown) of the underlay sheet 166. In the illustratedembodiment, the height of the exposed region is equal to the firstheight H101, although the height of the exposed region may be anydesired height. In a shingle wherein the cutouts have different heights,the upper edge 182A occurs with the cutout having the largest firstheight H101. In the illustrated embodiment, the overlay sheet 168 has asecond height H102.

A reinforcement material 119 may be disposed longitudinally on theheadlap portion 176. The reinforcement material 119 is configured toincrease the pull-through of the nail zone in the same manner as thetape 19 described above and illustrated in FIG. 2. In the illustratedembodiment, the reinforcement material 119 is formed from woven fabricmade from a polymeric material, such as the non-limiting example ofpolyethylene terephthalate (PET). In other embodiments, thereinforcement material 119 can be formed from other woven polymericmaterials, such as for example, polyester, polyolefin or polypropylene.In still other embodiments, the reinforcement material 119 can be formedfrom any material configured to reinforce and strengthen the nail zoneof a shingle, including the non-limiting example of paper, film, scrimmaterial, and woven or non-woven glass.

In the illustrated embodiment, the reinforcement material 119 extendslongitudinally from the first end to the second end of the shingle 174within the lower zone 176A of the headlap portion 176. A lower edge 119Aof the reinforcement material 119 may be spaced apart from the upperedge 182A of the cutouts by a first distance D101, and an upper edge119B of the reinforcement material 119 may be spaced apart from theupper edge 182A of the cutouts by a second distance D102. In oneembodiment, the first distance D101 is within the range of from about0.06 inches to about 0.75 inches. In another embodiment, the firstdistance D101 is about 0.25 inches. In one embodiment, the seconddistance D102 is within the range of from about 1.06 inches to about1.75 inches. In another embodiment, the second distance D102 is about1.50 inches. The first and second distances, D101 and D102, may however,be of any other desired length. For example, if desired, thereinforcement material 119 may substantially cover the entire headlapportion 176 of the overlay sheet 168. It should be understood, however,that one or more additional lengths of reinforcement material may bedisposed longitudinally on the headlap portion 176, such as shown inFIG. 2 by the phantom line 19′. In addition, the reinforcement material119 need not extend from the first end to the second end of the shingle174, and may be disposed in one or more sections or portions on theshingle 174.

The reinforcement material 119 defines a nail zone 198 and may includetext or other indicia such as described above for the tape 19 as shownin FIG. 2.

In the embodiment illustrated in FIG. 5, the underlay sheet 166 includesa lower edge 166A and an upper edge 166B. The distance from the loweredge 166A to the upper edge 166B defines a third height H103. The upperedge 166B of the underlay sheet 166 is spaced apart from the upper edge182A by a third distance D103. In the illustrated embodiment, the thirddistance D103 is within the range of from about 1.06 inches to about1.75 inches. In another embodiment, the third distance D103 is about1.38 inches. However, the third distance D103 may be any desireddistance.

Referring again to FIG. 5, the upper edge 166B of the underlay sheet 166is spaced apart from the upper edge 119B of the reinforcement material119 by a fourth distance D104. In the illustrated embodiment, the fourthdistance D104 is within the range of from about 0.06 inches to about0.50 inches. In another embodiment, the fourth distance D104 is about0.12 inches. In still other embodiments, the fourth distance D104 can bezero. However, the fourth distance D104 may be any desired distance.

In the illustrated embodiment, the third height H103 of the underlaysheet 166 is approximately one-half of the second height H102 of theoverlay sheet 168. The overlay sheet 168 and the underlay sheet 166thereby define a two-layer portion of the laminated shingle 174 and asingle-layer portion of the laminated shingle 174. Such a dimensionalrelationship between the underlay sheet 166 and the overlay sheet 168allows the reinforcement material 119 to be positioned such that thenail zone 198 can extend near or over the single-layer portion of theshingle 74. The two-layer portion of the laminated shingle 174 that iscovered by the reinforcement material 119 has a fourth height H104. Inthe illustrated embodiment, the fourth height H104 is in a range of fromabout 1.00 inches to about 1.75 inches. In other embodiments, the fourthheight H104 can be other dimensions less than about 1.00 inches or morethan about 1.75 inches.

Referring again to FIG. 5, the reinforcement material 119 has a fifthheight H105. In the illustrated embodiment, the fifth height H105 iswithin the range of from about 1.06 inches to about 1.87 inches. Inanother embodiment, the fifth height H105 is about 1.38 inches. However,the fifth height H105 may be any desired distance.

As discussed above, the relationship of the fourth height H104 and thefifth height H105 defines in part the extent to which the reinforcementmaterial 119 extends beyond the two-layer portion of the shingle 174 andinto the single layer portion of the shingle. In this regard, the term“coverage”, as used herein, is defined to mean the percentage of thereinforcement material 119 that covers the two-layer portion of theshingle 174. In other words, coverage is the ratio of the fourth heightH104 to the fifth height H105. As one example, a fourth height H104 of1.12 inches and a fifth height H105 of 1.25 inches provides a ratio of90%, meaning the 90% of the reinforcement material 119 is positioned tocover the two-layer portion of the shingle 174. In the illustratedembodiment, the coverage of the reinforcement material 119 is in a rangeof from about 70% to about 100%. In other embodiments, the coverage canbe in a range of from about 80% to about 95%. In still otherembodiments, the coverage can be in a range of from about 85% to about90%.

In the embodiment illustrated in FIG. 5, the shingle 174 may have a nailpull-through value that is the same as, or similar to, the nailpull-through value for the shingle 74 as described above and as shown inFIG. 2. Alternatively, the shingle 174 can have a nail pull-throughvalue that is different from the nail pull-through value for the shingle74.

In another embodiment, a shingle 174 having a reinforcement material 119formed from woven polymeric materials having a thickness of about 0.5mils, may have a nail pull-through value at least about 13 percentgreater than in an otherwise identical shingle having no suchreinforcement material 119.

In another embodiment, a shingle having a reinforcement material 119formed from woven polymeric materials having a thickness of about 3.0mils, may have a nail pull-through value about 62 percent greater thanin an otherwise identical shingle having no such reinforcement material119.

In another embodiment, a shingle having a reinforcement material 119formed from woven polymeric materials having a thickness of about 4.0mils, may have a nail pull-through value about 86 percent greater thanin an otherwise identical shingle having no such reinforcement material119.

In another embodiment, a shingle having a reinforcement material 119formed from woven polymeric materials having a thickness of about 5.0mils, may have a nail pull-through value about 112 percent greater thanin an otherwise identical shingle having no such reinforcement material119.

Because there may be substantially no granules in the portion of theoverlay sheet 168 covered by the reinforcement material 119, the weightof the shingle 174 may be reduced relative to an otherwise identicalshingle having no such reinforcement material 119. For example, theweight of the exemplary shingle 174 illustrated in FIG. 5, may bereduced within the range of from about four percent to about six percentrelative to the weight of an otherwise identical shingle having no suchreinforcement material 119. The material and transportation cost mayalso be reduced.

Although the invention has been disclosed in the context of a laminatedshingle 174, it will be understood that the reinforcement material 119may be attached to any other type of shingle, such as a single layershingle.

The principle and mode of operation of this invention have beendescribed in its various embodiments. However, it should be noted thatthis invention may be practiced otherwise than as specificallyillustrated and described without departing from its scope.

What is claimed is:
 1. A roofing shingle comprising: an overlay sheetincluding a mat and an asphalt coating applied to the mat, and defininga headlap portion and a tab portion; an underlay sheet including a matand an asphalt coating applied to the mat, the underlay sheet beingsecured to the overlay sheet such that a region of the underlay sheetoverlaps a region of the headlap portion of the overlay sheet; and areinforcement material secured directly to the asphalt coating on theheadlap portion of the overlay sheet without extending into the tabportion to provide a reinforced nail zone along a longitudinal axis ofthe shingle, with the reinforcement material and the headlap portionprovide a nail pull-through value that is greater than an otherwiseidentical shingle having no such reinforcement material; wherein thereinforcement material extends beyond the overlapping regions of theheadlap portion and the underlay, such that a first portion of thereinforcement material is disposed on a dual-layer portion of theshingle and a second portion of the reinforcement material is disposedon a single-layer portion of the shingle.
 2. The roofing shingle ofclaim 1, wherein the second portion of the reinforcement material iswider than the first portion of the reinforcement material.
 3. Theroofing shingle of claim 1, wherein the first portion of thereinforcement material extends into the dual-layer portion of theshingle by a distance of no greater than ⅛ inch.
 4. The roofing shingleof claim 1, wherein at least about 70% of the reinforcement material isdisposed on a dual-layer portion of the shingle.
 5. The roofing shingleof claim 1, wherein the reinforcement material comprises a wovenmaterial.
 6. The roofing shingle of claim 1, wherein the reinforcementmaterial comprises a non-woven material.